Upgrading of Heavy Crude Oil - Techno Forum 2017techno-forum.jogmec.go.jp/2014/_img/program/pre_9.pdf · Upgrading of Heavy Crude Oil ... Process Advantages ... (API 24o) High Temp

Upgrading of Heavy Crude Oil

- Supercritical Water Cracking Technology -

Hisato Aoyama

Manager, Technology Development Center

JGC CORPORATION

JOGMEC Techno Forum 2014, November 26th-27th 2014

Copyright 2014 JGC all rights reserved Supercritical Water Cracking

Organization--Background

The Super Critical Water Partial Upgrading technology has been developed by JGC Corporation of Japan, along with the financial, governmental and technical support of JOGMEC (Japan Oil, Gas and Metals National Corporation.) Laboratory testing and analysis have been completed and the technology is now moving into the actual demonstration phase set to commence in 2014.


JGC Business Areas

Gas Processing

Environmental & Energy Conservation

Medical Facilities & Research Laboratories

Refineries

Petrochemicals & Chemicals

Industrial

Power Generation

LNG

Up & Mid Stream

EPC

( Engineering / Procurement / Construction)

IWPP CO2 Solution

Water Business

Project

Development &

Investment

Urban Development

CSP Oil & Gas Development

3

http://www.pc.gc.ca/docs/v-g/ie-ei/cc/images/ghg_effect_sm_e.jpg


Supercritical Water Cracking

Background

Process Advantages

Supply Chain Benefits 5BPD Pilot Plant in Canada

Summary

4

Copyright 2014JGC all rights reserved Supercritical Water Cracking

Background


E.Europe/Eurasia

Middle East

North America

Latin America

Africa

source: IEA 2013

6

Asia

Europe

309

808

81 92 3 17

140 3 74

429 552

78

1139

14 0

308

2 38 251

498

57

Conventional Oil

Unconventional Heavy Oil

Tight Oil/Shale Oil

Recoverable oil resources Oil: billion barrels


Heavy Crude Oil Supply Schemes

Diluted Bitumen (DilBit)

Diluents

Sour SCO

(SCW)

Full Upgrader Scheme

Upstream Downstream

Diluted Scheme

Partial Upgrader Scheme

Full Upgrader

CDU, VDU, Coker, HDS

CDU, HDS

Sweet SCO

CDU

Midstream

SAGD

SAGD

Liquid Products

Partial Upgrader

SAGD

Liquid Products

Liquid Products

Cokes Sulfur (Waste)

Cokes Sulfur

Sulfur

7

Copyright 2014 JGC all rights reserved Supercritical Water Cracking 8

Feedstock Target

API o

8.3 > 21

Viscosity@10oC cSt 1,000,000 < 350

Sulfur wt% 5.15 -

Ni / V ppm 75 / 194 -

TAN mg/g 2.48 -

Olefins % < 0.5 <1.0

Feedstock Bitumen

Product SCO

Refinery

Pipeline

SCWC

Properties of Feedstock and Targets


Water Distillate VGO

Water, Residue

SCW forms layers in

the asphaltene micelle

1. Thermal Cracking of VR

3. Inhibiting polymerization of asphaltene (coking)

2. Extracting Distillate and VGO

Results of Direct Observation

Roles of Supercritical Water

9


What is Supercritical Water?

SCW

Pre

ssu

re

Solid (Ice)

Liquid (Water)

Gas (Steam)

Critical

temperature

(=374℃)

Critical pressure

(=22.1MPa)

Temperature

Water at a temperature and pressure above its critical point

Gas SC Fluid Liquid

Density kg/m3 1 100~1,000 1000

Viscosity mPa・s 0.01 0.1 1

Diffusion

Coefficientm

2/s 10

-510

-7~10

-810

-10

Thermal

ConductivitymW/mK 5~30 20~150 50~200

SCW has physical properties

between liquid and gas


Bench-Scale Test Unit


R&D Work Plan

•Preliminary Test

•Preliminary F/S

（Mar - Jul 2006)

•Long Term Operation

•Commercial Design

•Optimizing RX Conditions

•SCO Evaluation

•Reaction Modeling

Phase 2 Lab Phase Phase 1 Pre-Test

• Test of other heavy oils

• Comparison with conventional technologies

Phase 3 Demonstration

•Reliability Test

•Scale factor Evaluation

•Semi-Commercial Design

Phase 2.1 （Jan - Dec 2007）

2.2 （Sep 2007 - Mar 2008）

3.1 Pilot Plant 5BPD＠Canada (Nov 2011 - Mar 2016)

3.2 Semi-Commercial 2000 BPD Ｓｅｍｉ-Ｃｏｍｍｅｒｃｉａｌ Plant

•Preliminary Process Design

•Economic Evaluation

•Secondary Conversion Test

2.3 （Apr - Dec 2008）

•Higher Conversion Test

•Evaluation of Boiler & FDG

•Waste Water Treating

2.4 （Jan 2010 – Mar 2011)

12


Process Advantages


SCO 21KBPD (API 24o)

High Temp. Separator

Reactor

Bitumen Heater

Low Pressure Separator

WWT

Pitch Flash Drum

Water Heater

Sour Gas Treatment

SAGD System

SWS

Water 30 KBPD

Bitumen 30KBPD (API 8°)

Pitch 9 KBPD

BFW

30,000 BPSD SCWC Scheme

Diluent 14KBPD

DilBit 44 KBPD

Pitch Cooler

Product Cooler


0

20

40

60

80

100

120

FeedstockBitumen

SCW Cracking Products

Delayed CokerProducts*1

Yie

ld v

ol%

Distillate & Lighter

VGO

VR

100% 101%

80% (+ Coke 20 wt%）

19

34

47

46

36

19

40

40

*1 includes Coker products and straight run Distillate & Naphtha.

Liquid Yield Comparison

15


70m

100m

SCWC Plant Footprint


SCW (Base =100%)

Visbreaker

Coker0%

100%

200%

300%

400%

500%

600%

No

. of E

qu

ipm

en

tProcess Complexity


Supply Chain Benefits

18


Supply Chain Cost

(WTI:$80/bbl, Natural Gas: $4/MMBTU)

19

-10

0

10

20

30

40

50

60

70

-10

0

10

20

30

40

50

60

70

Diluted Bitumen

（One Through）

Sour SCO(SCWC)

Diluent

Pipeline

Upgrader

Pitch Boiler CAPEX

SAGD OPEX

SAGD CAPEX

Natural Gas

By-Product Sales

Total (Net Cost)

<Assumptions>

•Upgrader cost including utility, catalyst, maintenance cost and Depreciation (20yr straight-line).

•Diluents cost: $85/bbl (=WTI +$5/bbl) (30 vol % dilution blend ratio)

•Natural Gas Price: $4/MMBTU (Fuel duty of SAGD Boiler to be 1400MMBTU/hr )

•Pipeline cost : $5/bbl (Fort McMurray ～Edmonton), $8/bbl (Edmonton～Houston)

•OPEX of SAGD: $8.8/bbl-Bitumen (excl. Boiler Fuel Cost) , CAPEX of SAGD (sustaining) : $6.3/bbl-Bitumen

US

$/ B

BL

-SC

O


Supply Chain Cost Advantage to Diluted Bitumen (WTI:$80/bbl, Natural Gas: $4/MMBTU)

20

SAGD Fuel （Natural Gas →Residue）

Pipeline Volume Saving

（by 40%)

No Diluents Supply Cost

△$ 12/ bbl

Upstream ⇒ Pipeline ⇒ Refinery

SCO Premium $ 8/ bbl

0

20

40

60

80

100

SCO DilutedBitumen

VRVGO

VGO

Distillate

Distillate

Naphtha

Yie

ld V

ol%

Sulfur(wt%) 3.3 3.8 API ° 24 22 Product v% 100 86

US

$/ B

BL

-SC

O


5 BPD Pilot Plant in Canada


6.7m

8.3m 3.2m

5 bpd SCWC Pilot


5bpsd SCWC Pilot

Bitumen Service Tank

Water Tank

Electrical Heater

Reactor

High Pressure Separator：

Knock out Drum：

Flash Drum：

Pitch Flash Drum:

Receiver：

Gas

SCO

SCO

Water

Pitch

Electrical Heater

Low Pressure Separator：

Copyright 2014 JGC all rights reserved Supercritical Water Cracking 24

Existing Building (Pilot Plant Site)

Pilot Plant Site in Canmet Facility


Summary


Footprint (Excl. Tank Yard)

Solid Waste (By-product)

Coke Sulfur

Sulfur

Energy Consumption (API 8

o 21

o)

SCWC Delayed Coker

SCW ~ Simple, Clean, minimal Waste ~

26

1

1 4 150

1 1.5

4


Summary

27

Minimal Waste SCWC is a partial upgrading technology aimed at minimizing on-

site cokes and sulfur

Simple Process SCWC is a simple process applicable for on-site (SAGD)

production

Supply Chain Advantages Supply cost improved by $20/bbl

Energy consumption reduced by 30%

Ready for Demonstration SCWC Pilot Plant is ready for demonstration

Contact: Hisato Aoyama ([email protected])

Documents

Upgrading of Heavy Crude Oil - Techno Forum 2017techno-forum.jogmec.go.jp/2014/_img/program/pre_9.pdf · Upgrading of Heavy Crude Oil ... Process Advantages ... (API 24o) High Temp